Eclipse Furnnox Operating instructions

Brand: Eclipse

Model: Furnnox

Type: Operating instructions

Eclipse Furnnox

Burner

210 Installation Guide

2/14/2011

Version 1

worldwide. This publication is protected by federal

regulation and shall not be copied, distributed,

transmitted, transcribed or translated into any human or

computer language, in any form or by any means, to any

third parties, without the express written consent of

Eclipse, inc.

Disclaimer Notice

In accordance with the manufacturer’s policy of continual

product improvement, the product presented in this

brochure is subject to change without notice or obligation.

The material in this manual is believed adequate for the

intended use of the product. If the product is used for

purposes other than those specified herein, confirmation

of validity and suitability must be obtained. Eclipse

warrants that the product itself does not infringe upon any

United States patents. No further warranty is expressed or

implied.

Liability & Warranty

We have made every effort to make this manual as

accurate and complete as possible. Should you find errors

or omissions, please bring them to our attention so that we

may correct them. In this way we hope to improve our

product documentation for the benefit of our customers.

Please send your corrections and comments to our

Technical Documentation Specialist.

It must be understood that Eclipse’s liability for its product,

whether due to breach of warranty, negligence, strict

liability, or otherwise is limited to the furnishing of

replacement parts and Eclipse will not be liable for any

other injury, loss, damage or expenses, whether direct or

consequential, including but not limited to loss of use,

income, or damage to material arising in connection with

the sale, installation, use of, inability to use, or the repair

or replacement of Eclipse’s products.

Any operation expressly prohibited in this manual, any

adjustment, or assembly procedures not recommended or

authorized in these instructions shall void the warranty.

Document Conventions

There are several special symbols in this document. You

must know their meaning and importance.

The explanation of these symbols follows below. Please

read it thoroughly.

How To Get Help

If you need help, contact your local Eclipse

representative. You can also contact Eclipse at:

1665 Elmwood Rd.

Rockford, Illinois 61103 U.S.A.

Phone: 815-877-3031

Fax: 815-877-3336

http://www.eclipsenet.com

Please have the information on the product label available

when contacting the factory so we may better serve you.

Product Name

Item #

S/N

DD MMM YYYY

www.eclipsenet.com

This is the safety alert symbol. It is used to alert you to potential personal

injurt hazards. Obey all safety messages that follow this symbol to avoid

possible injury or death.

Indicates a hazardous situation which, if not avoided, will result in death

or serious injury.

Indicates a hazardous situation which, if not avoided, could result in

death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in

minor or moderate injury.

Is used to address practices not related to personal injury.

Indicates an important part of text. Read thoroughly.

NOTE

NOTICE

CAUTION

WARNING

Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

1 Introduction............................................................................................................................ 4

Product Description .............................................................................................................. 4

Audience .............................................................................................................................. 4

Purpose................................................................................................................................ 4

Related Documents.............................................................................................................. 4

2 Safety...................................................................................................................................... 5

Safety Warnings ................................................................................................................... 5

Capabilities........................................................................................................................... 5

Operator Training ................................................................................................................. 5

Replacement Parts...............................................................................................................5

3 Installation.............................................................................................................................. 6

Introduction........................................................................................................................... 6

Handling & Storage ..............................................................................................................6

Checklist Before Installation ................................................................................................. 7

Position of Components ....................................................................................................... 6

Approval of Components...................................................................................................... 6

Electrical Supply................................................................................................................... 7

Prepare the Burner............................................................................................................... 7

Combustion Block Installation .............................................................................................. 9

Checklist After Installation ....................................................................................................10

Refractory Block Curing Schedule ....................................................................................... 10

4 Adjustment, Start & Stop ......................................................................................................11

Modulating Gas & Air Ratio System ..................................................................................... 11

Set the Bypass Pilot Gas (Optional)..................................................................................... 13

Start Procedure .................................................................................................................... 14

Stop Procedure .................................................................................................................... 14

5 Maintenance & Troubleshooting.......................................................................................... 15

Introduction........................................................................................................................... 15

Maintenance......................................................................................................................... 15

Monthly Checklist ................................................................................................................. 15

Yearly Checklist.................................................................................................................... 15

Troubleshooting Guide......................................................................................................... 16

Appendix ................................................................................................................................... i

Conversion Factors ..............................................................................................................i

Table of Contents

4Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Product Description

The Furnnox is a Low NOx nozzle-mix burner using

ambient or preheated combustion air with temperatures

up to 1100°F (600°C). The Furnnox burner is designed for

application on direct fired high temperature range, 1400°F

to 2800°F (760°C to 1540°C), furnaces.

By staging the combustion air the burner NOx emissions

are reduced compared to standard nozzle mixing burners.

Staging of the combustion air is achieved by secondary air

holes in the burner refractory block.

The Furnnox burner is designed for direct ignition and

flame supervision by UV scanner.

Figure 1.1. Standard & Insulated Furnnox Burner

Audience

This manual has been written for personnel already

familiar with all aspects of a gas burner and it’s add-on

components, also referred to as the burner package.

These aspects are:

• Installation

• Use

• Maintenance

• Safety

The audience is expected to be qualified and have

experience with this type of equipment and its working

environment.

Purpose

The purpose of this manual is to make sure that you carry

out the installation of a safe, effective and trouble-free

system.

Furnnox Documents

Installation Guide No. 210

• This document

Datasheet Series No. 210

• Available for individual Furnnox models

• Required to complete installation

Spare Parts List Series No. 210

• Recommended replacement part information

Related Documents

• EFE 825 (Combustion Engineering Guide)

• Eclipse Bulletins and Information Guides: 210, 610,

710, 720, 730, 742, 744, 760, 930, I-354

BLOCK UP

BLOCK DOWN

Standard

Insulated

Introduction

Safety

Important notices which help provide safe burner

operation will be found in this section. To avoid personal

injury and damage to the property or facility, the following

warnings must be observed. All involved personnel should

read this entire manual carefully before attempting to start

or operate this system. If any part of the information in this

manual is not understood, contact Eclipse before

continuing.

Safety Warnings

■ The burners, described herein, are designed to mix

fuel with air and burn the resulting mixture. All fuel

burning devices are capable of producing fires and

explosions if improperly applied, installed,

adjusted, controlled or maintained.

■ Do not bypass any safety feature; fire or explosion

could result.

■ Never try to light a burner if it shows signs of

damage or malfunction.

■ The burner and duct sections are likely to have

HOT surfaces. Always wear the appropriate

protective equipment when approaching the

burner.

■ Eclipse products are designed to minimize the use

of materials that contain crystalline silica.

Examples of these chemicals are: respirable

crystalline silica from bricks, cement or other

masonry products and respirable refractory

ceramic fibers from insulating blankets, boards, or

gaskets. Despite these efforts, dust created by

sanding, sawing, grinding, cutting and other

construction activities could release crystalline

silica. Crystalline silica is known to cause cancer,

and health risks from the exposure to these

chemicals vary depending on the frequency and

length of exposure to these chemicals. To reduce

the risk, limit exposure to these chemicals, work in

a well-ventilated area and wear approved personal

protective safety equipment for these chemicals.

■ This manual provides information regarding the

use of these burners for their specific design

purpose. Do not deviate from any instructions or

application limits described herein without written

approval from Eclipse.

Capabilities

Only qualified personnel, with sufficient mechanical

aptitude and experience with combustion equipment,

should adjust, maintain or troubleshoot any mechanical or

electrical part of this system. Contact Eclipse for any

needed commissioning assistance.

Operator Training

The best safety precaution is an alert and trained

operator. Train new operators thoroughly and have them

demonstrate an adequate understanding of the

equipment and its operation. A regular retraining schedule

should be administered to ensure operators maintain a

high degree of proficiency. Contact Eclipse for any needed

site-specific training.

Replacement Parts

Order replacement parts from Eclipse only. All Eclipse

approved valves or switches should carry UL, FM, CSA,

CGA and/or CE approval where applicable.

DANGER

WARNING

NOTICE

6Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Introduction

In this section you will find the information and instructions

needed to install the burner and system components.

■ Only qualified competent personnel with

experience of combustion systems are allowed to

install, adjust or maintain the burner.

■ All installation work must be carried out in

compliance with current legislated standards.

Handling & Storage

Handling

• Make sure the area is clean.

• Inspect the burner, ensure that all components are

clean and free from damage.

• Use appropriate support and handling equipment

when lifting the burner.

• Protect the burner from weather, damage, dirt and

moisture.

• Protect the burner and components from excessive

temperatures and humidity.

Storage

• Make sure the components are clean and free of

damage.

• Store the components in a cool, clean, dry room.

• After making sure everything is present and in good

condition, keep the components in original

packages as long as possible.

Position of Components

The position and amount of components are determined

by the kind of control method chosen. Furnnox burners

are applied on furnaces using multiple burners and

multiple control zones, for which electronic gas air ratio

control systems are used.

Due to the variety of these control systems this manual

does not describe the design.

Approval of Components

Limit Controls & Safety Equipment

All limit controls and safety equipment must comply with

all applicable local codes and/or standards and must be

listed for combustion safety by an independent testing

agency. Typical application examples include:

• American: NFPA 86 with listing marks from UL, FM,

CSA

• European: EN 746-2 with CE mark from TuV,

Gastec, Advantica

Electrical Wiring

All the electrical wiring must comply with all applicable

local codes and/or standards such as:

• NFPA Standard 70

• IEC60364

• CSA C22

• BS7671

Gas Piping

All the gas piping must comply with all applicable local

codes and/or standards such as:

• NFPA Standard 54

• ANSI Z223

• EN 746-2

Where to Get the Standards:

The NFPA Standards are available from:

National Fire Protection Agency

Batterymarch Park

Quincy, MA 02269

www.nfpa.org

The ANSI Standards are available from:

American National Standard Institute

1430 Broadway

New York, NY 10018

www.ansi.org

The UL Standards are available from:

333 Pfingsten Road

Northbrook, IL 60062

www.ul.com

WARNING

Installation

Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

The FM Standards are available from:

1151 Boston-Providence Turnpike

PO Box 9102

Norwood, MA 02062

www.fmglobal.com/approvals

Information on the EN standards and where to get

them is available from:

Comité Européen de Normalisation

Stassartstraat 36

B-1050 Brussels

Phone: +32-25196811

Fax: +32-25196819

www.cen.eu

Comité Européen de Normalisation Electronique

Stassartstraat 36

B-1050 Brussels

Phone: +32-25196871

Fax: +32-25196919

www.cenelec.org

Checklist Before Installation

Air Supply

To admit fresh combustion air from outdoors, provide

sufficient opening in the room to allow fresh air to enter

according to local regulations.

If there are corrosive fumes or materials in the air, then

supply the burner with clean air from an uncontaminated

area.

Exhaust

Do not allow exhaust fumes to accumulate in the work

area. Provide some positive means for exhausting from

the furnace and the building.

Access

Make sure that you install the burner in such a way that

you can gain easy access for inspection and

maintenance.

Environment

Make sure the local environment matches the original

operating specifications. Check the following items:

• Voltage, frequency and stability of the electrical

power

• Fuel type and supply pressure of the fuel

• Availability of enough fresh, clean combustion air

• Humidity, altitude and temperature of air

• Presence of damaging corrosive gases in the air

• Prevent direct exposure to water

Fuel Type

If using an alternative fuel supply, contact Eclipse with an

accurate breakdown of the fuel components.

Electrical Supply

The burner should be controlled via a sequence

programmer, approved according to the local standards.

For connections, please refer to the related wiring

diagrams.

■ Wiring to the burner must be in accordance with

current wiring standards. It is vital that the live and

neutral wires are connected correctly as reversal

could present a hazard. Also the grounding must

be checked to ensure a good connection.

■ Gas pipe work must NOT be used for grounding

purposes.

■ If burner control signals are supplied via a flame

safeguard control panel provided by others,

Eclipse can not accept any responsibility for

incorrect interfacing.

Prepare the Burner

Several components must be installed on a burner before

it can operate. Installation instructions follow.

It is possible to change the relative position of the gas inlet

with respect to the air inlet. This can be convenient for the

routing of the piping.

Rotate the Rear Cover

(On Standard Body Only, Optional)

To rotate the rear cover, do the following (see Figure 3.1):

1. Disconnect the piping at a union in the piping or the

inlet flanges  provided on the burner.

NOTE: Be careful not to lose or damage the orifice

plate or the o-rings.

2. Remove the four bolts .

Fuel Symbol Gross Heating

Value

Specific

Gravity

WOBBE

Index

Natural

Gas CH490%+ 1000 BTU/ft3

(40.1 MJ/m3)0.60 1290

BTU/ft3

Propane C3H8

2525 BTU/ft3

(101.2 MJ/m3)1.55 2028

BTU/ft3

Butane C4H10

3330 BTU/ft3

(133.7 MJ/m3)2.09 2303

BTU/ft3

BTU/ft3 at standard conditions (MJ/m3 at normal

conditions)

WARNING

8Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

3. Remove the rear cover  from the burner housing .

4. Rotate the rear cover  to the position that you want.

5. Put the rear cover  in position against the burner

housing .

6. Install the four bolts .

7. Reconnect the piping. Make sure that the o-rings

show no signs of damage.

Figure 3.1. Rotate the Rear Cover

Installing the Flame Sensor

Figure 3.2. Installing the Flame Sensor

1. Install the flame sensor into the 1/2" NPT opening in the

rear cover.

2. Make sure that you connect the flame sensor of a

burner to the electrical circuit of that burner.

■ If you connect the flame sensor of a burner to the

electrical circuit of the wrong burner, then you can

cause fires and explosions.

■ Adjustments may vary from Eclipse published

values if the flame controls other than those

recommended in the Design Guide are used.

Consult with the engineer who specified the

alternate control for limitations.

UV Scanner

For detailed information on how to install and connect a

UV scanner, refer to scanner information guide.

Installing the Spark Plug

Install the spark plug into the opening in the rear cover.

NOTE: Do not apply any grease to the threads of the

spark plug. You can cause bad grounding of the spark

plug if you apply grease to it. Bad grounding of the spark

plug results in a weak spark.

➋

➌

➍

➊

➋

➌

➍

Flame

Sensor

Spark

Plug

DANGER

NOTICE

Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Combustion Block Installation

For Hard Refractory Lined Furnaces:

(See Figure 3.3)

• Allow approximately 1/2" (12mm) clearance all

around the refractory combustor.

• Be sure the gasket  is installed between the

burner  and the refractory combustor flange .

• Install the gasket between the refractory

combustor flange  and the furnace shell .

• Support the weight of the refractory combustor 

with hard brickwork anchored to the furnace shell

. Fill the 1/2" space between the refractory

combustor  and the three unsupported sides with

soft gasket material .

Figure 3.3 Hard Refractory Lined Furnaces

■ After initial firing of furnace at design temperature,

check fiber shrinkage in vicinity of burner tile. Fill

any voids with bulk fiber insulation to maintain a

gas tight seal between furnace interior and shell.

For Fiber Lined Furnaces:

(See Figure 3.4 and Figure 3.5)

• Be sure the gasket  is installed between the

burner  and be refractory combustor flange .

• Install the gasket  between the refractory

combustor flange  and the furnace shell .

• Coat the outside of the refractory combustor  with

an air setting refractory cement . Also, fill

clearance gap between the furnace shell  opening

and the refractory combustor  with cement.

• Wrap the exposed refractory combustor  length

with two layers of continuous strip of blanket

insulation .

• Compress and secure the blanket insulation  to

the refractory combustor  using a suitable, non-

metallic tape. Compression of the blanket insulation

 should be at least 25%.

• Install the fiber insulation  tightly against the

wrapped refractory combustor , following the

suppliers recommended procedure for anchoring

and compressing the fiber .

Figure 3.4 Fiber Lined Furnaces

• For applications exceeding 2200 °F (1200 °C) install

a ceramic fiber board shield 11 suitable for the

furnace design temperature as illustrated in Figure

3.5.

• Anchor the shield 11 to the refractory combustor 

and the fiber lining  with a high temperature, air

setting refractory cement 12 and ceramic anchoring

devices 13 .

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













NOTICE



















10 Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Figure 3.5

NOTE: For furnaces that are unable to support the weight

of the refractory block, a stainless steel shelf can be

welded to the shell for support.

■ After initial firing of the furnace at design

temperature, check for fiber shrinkage in the

vicinity of the refractory combustor. Fill any voids

with bulk fiber insulation to maintain a gas-tight

seal between the furnace interior and shell.

Piping Installation

Straight Run of Pipe Before a Metering

Orifice

NOTE: There must be a run of pipe with a straight length

of at least 10 pipe diameters before the burner metering

orifice. If you do not do this, the pressure readings will be

inaccurate.

Pipe Connections

Install a pipe union in the gas line to the burner. This

simplifies removal of the burner.

The use of flexible pipe nipples in the gas line to the

burner is optional. Flexible nipples can absorb stress due

to heat expansion and slight misalignment.

NOTE: The pressure drop of the gas in the piping is a

critical parameter. Make sure that the size of all the piping

is large enough to prevent excessive pressure loses.

Checklist After Installation

To verify the system was properly installed, perform the

following checks:

1. Make sure that there are no leaks in the gas lines and

the air lines.

2. Make sure all the components of the flame monitoring

control system are properly installed. This includes

verifying that all switches are installed in correct

locations and all wiring, pressure, and impulse lines

are properly connected.

3. Make sure components of the spark ignition system

are installed and functioning properly.

4. Make sure that the blower rotates in the correct

direction. If incorrect, then have a qualified electrician

rewire the blower to reverse its rotation.

5. Make sure all valves are installed in proper locations

and are properly oriented relative to the gas or air flow

direction.

Refractory Block Curing Schedule

The refractory block was cured at the factory up to a

temperature of 650°F (345°C). Final curing should be

done after installation.

The recommended curing schedule is:

• Ambient to 600°F (315°C) at 100°F (55°C) per hour.

• 600°F (315°C) to 1000°F (540°C) at 25°F (14°C) per

hour. Hold the refractory block at 1000°F (540°C) for

12 hours.

• Cool or raise the operating temperature at a rate of

100°F (55°C) per hour.

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NOTICE

Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

In this chapter you will find instructions on how to adjust a

system, and how to start and stop a system.

■ Do not bypass any safety feature. You can cause

fires and explosions.

Modulating Gas & Air Ratio System

If you adjust an on-ratio system for the first time, you must

follow these steps:

Step 1: Reset the System

1. Close the automatic gas valves and gas cocks.

2. Fully open the manual air butterfly valve at each burner.

a.Drive the automatic zone air control valve to high

fire.

b.Adjust the automatic zone air control valve so that it

is fully open.

3. Start the blower.

■ Make sure that the blower rotates in the correct

direction. If incorrect, have a qualified electrician

rewire the blower to reverse its rotation.

4. Adjust the eductor flow valve to set the flow measured

across the orifice to the flow specified by Eclipse for

your application.

Step 2: Set High Fire Air

1. Set the system to high fire, but DO NOT ignite the

burner(s).

2. Use the orifice flow data (provided by orifice

manufacturer) to determine the pressure drop across

the orifice necessary for high fire air flow.

NOTE: If using single diaphragm ratio regulator control,

set air flow to 35% excess air to account for temperature

changes in combustion air.

3. Set high fire air using the manual combustion air

butterfly to achieve the pressure differential determined

in Step 2.

NOTE: A pressure tap is open when the screw inside the

tap is unscrewed approximately half a turn.

Figure 4.1. Set High Fire Air

NOTE: Insulated Body Furnnox Burners do not have a

Tap(s) A. For insulated housing version, use pressure

taps in supply lines to the burner(s).

Burner system:

a.Standard Version, open all pressure tap(s) A.

Insulated Housing Version, use pressure taps in

the supply lines to the burner.

b.Measure and note the static pressure at Tap A for all

the burners.

c.If all the measured static pressures are within 0.3"

w.c. (0.75 mbar) of each other, then proceed to the

next section. If the variation is greater than 0.3" w.c.

(0.75 mbar) it will be necessary to adjust the manual

air butterfly valve at each burner to improve the

balance.

d.Make sure that all the pressure taps are closed.

4. Repeat the proceeding for other zones (if any).

DANGER

NOTICE

Tap A

Adjustment, Start &

Stop 4

12 Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Figure 4.2. Burner System

Step 3: Set Low Fire Air

1. Set the system to low fire.

2. Connect the manometer to tap A (air inlet pressure

tap).

3. Adjust the automatic zone air control valve until the low

fire static air pressure is 0.2" w.c. This is the initial

setting only. Further adjustment may be required.

4. Repeat 2 and 3 for the other zones (if any).

Step 4: Verify the Air Settings

Make sure all the settings are still the same after you cycle

the system several times between high and low fire.

Step 5: Ignite the Burners

■ This procedure assumes that a flame monitoring

control system is installed and is serviceable. It

also assumes that normal low fire start is being

used. If low fire gas is too low to be used for

ignition, refer to options in “Set the Bypass Pilot

Gas (Optional)” on page 13.

1. Drive the zone air automatic control valve to low fire.

2. Make sure the combustion air blower is running.

3. Set the manual gas butterfly valve at each burner to

50% open.

Figure 4.3. Adjusting Ratio Regulator Screw

4. Adjust the ratio regulator as required for low fire.

5. Open manual gas cock at each burner.

6. Initiate the ignition sequence through the flame

monitoring control system.

7. Check that all the burners in the zone have ignited. If all

the burners have ignited, drive the combustion air

butterfly valve to high fire. Verify flame is present at

each burner. If burners do not light, increase the gas

flow by adjusting the ratio regulator, repeat step 6.

8. Recheck the high fire air settings.

NOTE: As application temperature increases, pressure

will change. Depending on control method, readjustment

of the manual combustion air butterfly valve may be

necessary.

to other Burners

Eductor Flow

Control Valve Heat

Exchanger/

Eductor

Main Gas

Shut-Off

Valve Train

Manual Combustion

Air Control Valve

WARNING

Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Step 6: Set High Fire Gas

Figure 4.4. Set High Fire Gas

1. Use the gas curve from the appropriate Furnnox

datasheet for the gas being used to find the differential

gas pressure needed at high fire. This is the target

value for high fire.

2. Connect the manometer to taps B and D (across the

gas orifice).

3. Measure the high fire differential gas pressure for the

first burner.

4. Adjust the gas butterfly valve at the burner until the gas

flow is at the target value.

5. Repeat 3 thru 4 for the other burners in the zone.

6. Check the gas pressure at the inlet to the zone ratio

regulator. This should be at least 5" w.c. (12.5 mbar)

higher than the loading line pressure. It should not

exceed the maximum pressure rating of the ratio

regulator.

■ Insufficient gas inlet pressure may cause the

proportionator to remain fully open as the burner

system turns down from high fire, causing excess

fuel operation and possible accumulation of

unburned fuel in the chamber. In extreme cases,

this may cause explosions or fires.

Step 7: Set Low Fire Gas

1. Drive the system to low fire.

2. Use the gas curve from the appropriate Furnnox

datasheet for the gas being used to determine the

differential gas pressure required for low fire. This is

your target value for low fire.

3. Measure the gas pressure at the first burner.

4. Adjust the ratio regulator until the gas flow is on the

target value.

NOTE: It is very difficult to measure the very low

pressures experienced at low fire, and it may be

necessary to rely on visual inspection. The main intent is

to provide a clean stable flame with a good flame signal

that will not cause the furnace temperature to overshoot.

If the pressure required is too low to be measured, adjust

the ratio regulator until a gas flow is obtained that will

provide a clean stable flame with a strong flame signal.

Step 8: Verify the Gas Settings

Make sure that all settings are still the same after cycling

the system several times between high and low fire.

Step 9: Readjust Settings

As application temperature increases, setting may vary.

Recheck and readjust as temperatures increase.

NOTE: When all the settings have been completed, mark

the position of the indicator on the butterfly valves to

indicate valve position.

Set the Bypass Pilot Gas (Optional)

1. Set the system to low fire.

2. Make sure that the blower is on.

■ Before you perform this procedure, make sure the

flame monitoring control system is working.

3. Use the flame monitoring control system to start the

ignition and the bypass pilot gas for all the burners in

the zone.

4. Adjust the manual butterfly valve in the bypass line until

you obtain reliable ignition within the required trial for

ignition time limit.

5. Repeat 4 for all the other burners and zones (if any).

Tap “D”

Tap “B”

Manometer

WARNING WARNING

14 Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Start Procedure

1. Start the blower.

2. Open all the gas cocks.

3. Start the ignition sequence.

4. Verify that flame is present at each burner.

■ If a burner does not light, and the system does not

shut down automatically, then you must close the

main gas cock. An uncontrolled flow of gas can

cause fires and explosions.

■ Do not touch the ignition plug or the ignition wire

when the ignition is on. You will get a shock.

Stop Procedure

1. Close the following valves:

• The manual gas cock for each burner or zone

• The manual gas cock at the main control valve

• All the manual shut-off valves in the gas line

upstream of the burner gas cock

2. Let the burners cool down. Keep the blower on until the

chamber temperature is less than 1000°F (500°C) and

then stop the blower.

■ Keeping the blower on after the burner is off

protects the burner and the other components

from hot gases that flow back through the burner.

DANGER

NOTICE

Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Introduction

This section is divided into two parts:

• The first part describes the maintenance

procedures.

• The second part helps identify problems that may

occur and gives advice on how to solve these

problems.

Maintenance

Preventive maintenance is the key to a reliable, safe and

efficient system. The core of any preventive maintenance

program is a list of periodic tasks.

The following are suggestions for a monthly list and a

yearly list.

NOTE: The monthly list and the yearly list are an average

interval. If your environment is dirty, then the intervals may

be shorter. Other standards may take precedence for your

particular application.

Monthly Checklist

• Test (leak test) safety shut-off valves for tightness of

closure.

• Test air pressure switch settings by checking switch

movements against pressure settings and

comparing with actual impulse pressure.

• Visually check ignition cable and connectors.

• Inspect impulse piping for leaks.

• Make sure that the following components are not

damaged or distorted:

- the spark plugs

- the flame sensors

- if applicable, remove and clean all the orifice

plates

Yearly Checklist

Perform all monthly checklists plus:

• Inspect flame-sensing devices for good condition

and cleanliness.

• Check for proper inlet air/gas ratios.

• Test all the alarm systems for proper signals.

• Check ignition spark plugs and check proper gap.

• Check valve motors and control valves for free,

smooth action, and adjustment.

• Check for proper operation of the ventilating

equipment.

• Test the interlock sequence of all safety equipment;

manually make each interlock fail, noting that

related equipment closes or stops as specified by

the manufacturer.

• Test flame monitoring control system by manually

shutting off gas to the burner.

• Test main fuel hand-valves for operation.

• Clean or replace the combustion air blower filter.

• Remove, clean and inspect all the burners.

• Make sure that the following components are not

damaged or distorted:

- the burner nozzle

- the flame tube or combustion block

Maintenance &

Troubleshooting

16 Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Troubleshooting Guide

Problem Possible Cause Solution

Cannot initiate start sequence Main power is off Make sure power is on to control

system.

No power to control Call qualified electrician to investigate.

Air pressure switch has not made

contact

Check air-pressure switch adjustment.

Check air filter.

Check blower rotation.

Check outlet pressure from blower.

High gas pressure switch has tripped Check incoming gas pressure.

Adjust gas pressure if necessary.

Check pressure switch setting and

operation.

Low gas pressure switch has activated Check incoming gas pressure.

Adjust gas pressure if necessary.

Check pressure switch setting and

operation.

Malfunction of flame monitoring control

system such as shorted out flame

sensor or electrical noise in the sensor

line

Have a qualified electrician investigate

and rectify.

Purge cycle not completed Check flame monitoring control

system, purge timer, interlocks and

limit switches.

Start-up sequence runs but burner

does not light

No ignition:

• There is no power to the ignition

transformer

Restore power to the ignition

transformer.

No ignition:

• Open circuit between the ignition

transformer and the spark plug

Repair or replace the wiring and

connectors to the spark plug.

No ignition:

• The spark plug needs cleaning

Clean the spark plug.

No ignition:

• The spark plug is not correctly

grounded to the burner

Clean the threads of the spark plug

and the burner.

Do not apply grease to the thread of

the spark plug.

Too much gas:

• Improper gas valve train sequence

Verify solenoid valve is downstream of

proportionator.

Too much gas:

• Manual gas butterfly valves have

been opened too far

Check pressures and settings against

start-up report and adjust as

necessary.

Too much gas:

• Gas pressure out of the main gas

pressure regulator is too high

Check start-up setting.

If necessary, remove regulator and

investigate.

Not enough gas:

• The gas pressure out of the main gas

pressure regulator is too low

Check start-up settings.

Check regulator and adjust if

necessary.

Eclipse Furnnox Burner, V1, Installation Guide 210, 2/14/2011

Start-up sequence runs but burner

does not light

Not enough gas:

• Start gas solenoid valve does not

open

Check solenoid valve coil for proper

operation. Replace if necessary.

Not enough gas:

• Gas valve not open

Check wiring to the automatic gas

shut-off valve.

Not enough gas:

• Air in the gas line

Check output from the flame

safeguard.

Open gas cock.

Purge gas line.

The low fire flame is weak or unstable • Low fire adjusted too low Increase low fire gas setting.

• Not enough gas Check start-up settings and adjust to

increase low gas flow.

• Not enough air Check start-up settings.

Investigate any change, i.e. blocked

filter, loose connections

The burner goes off when it cycles to

high fire

• Insufficient air (flame too rich) Check start-up settings.

Check air filter, clean, or replace if

required.

The burner is erratic and does not

respond to adjustment

• Flame signal weak Check condition of flame monitoring

device.

• Internal damage to the burner. Some

parts inside the burner may be loose or

dirty

Contact your Eclipse representative or

the Eclipse factory.

The burner is unstable or produces

soot or smoke

• The air/gas ratio is out of adjustment Measure all the gas pressures and air

pressures.

Compare to initial start-up settings,

and adjust them where necessary.

Cannot achieve full capacity • Air filter is blocked Clean or replace the air filter.

• Gas pressure is too low into the main

gas pressure regulator

Adjust gas pressure.

• Increased furnace/chamber

pressures

Re-check setup pressures.

• Poor piping practices Contact factory.

Problem Possible Cause Solution

Conversion Factors

Metric to English

Metric to Metric

English to Metric

From To Multiply By

actual cubic meter/h (am³/h) actual cubic foot/h (acfh) 35.31

normal cubic meter/h (Nm³/h) standard cubic foot /h (scfh) 38.04

degrees Celsius (°C) degrees Fahrenheit (°F) (°C x 9/5) + 32

kilogram (kg) pound (lb) 2.205

kilowatt (kW) Btu/h 3415

meter (m) foot (ft) 3.281

millibar (mbar) inches water column ("w.c.) 0.402

millibar (mbar) pounds/sq in (psi) 14.5 x 10-3

millimeter (mm) inch (in) 3.94 x 10-2

MJ/Nm³ Btu/ft³ (standard) 26.86

From To Multiply By

kiloPascals (kPa) millibar (mbar) 10

meter (m) millimeter (mm) 1000

millibar (mbar) kiloPascals (kPa) 0.1

millimeter (mm) meter (m) 0.001

From To Multiply By

actual cubic foot/h (acfh) actual cubic meter/h (am³/h) 2.832 x 10-2

standard cubic foot /h (scfh) normal cubic meter/h (Nm³/h) 2.629 x 10-2

degrees Fahrenheit (°F) degrees Celsius (°C) (°F - 32) x 5/9

pound (lb) kilogram (kg) 0.454

Btu/h kilowatt (kW) 0.293 x 10-3

foot (ft) meter (m) 0.3048

inches water column ("w.c.) millibar (mbar) 2.489

pounds/sq in (psi) millibar (mbar) 68.95

inch (in) millimeter (mm) 25.4

Btu/ft³ (standard) MJ/Nm³ 37.2 x 10-3

Appendix

Symbol Appearance Name Remarks Bulletin/

Info Guide

Gas Cock Gas cocks are used to manually shut off the

gas supply. 710

Ratio Regulator

A ratio regulator is used to control the air/gas

ratio. The ratio regulator is a sealed unit that

adjusts the gas pressure in ratio with the air

pressure. To do this, it measures the air

pressure with a pressure sensing line, the

impulse line. This impulse line is connected

between the top of the ratio regulator and the

burner body.

742

Main Gas Shut-Off Valve

Train

Eclipse strongly endorses NFPA as a

minimum. 790/791

Pilot Gas Valve Train Eclipse strongly endorses NFPA as a

minimum. 790/791

Automatic Shut-Off

Valve

Shut-off valves are used to automatically shut

off the gas supply on a gas system or a

burner.

760

Orifice Meter Orifice meters are used to measure flow. 930

Combustion Air Blower The combustion air blower provides the

combustion air to the burner(s). 610

Main Gas

Shut-Off

Valve

Train

Pilot Gas

Shut-Off

Valve Train

System Schematics

iii

Hermetic Booster Booster is used to increase gas pressure. 620

Automatic Butterfly Valve Automatic butterfly valves are typically used

to set the output of the system. 720

Manual Butterfly Valve Manual butterfly valves are used to balance

the air or gas flow at each burner. 720

Adjustable Limiting

Orifice

Adjustable limiting orifices are used for fine

adjustment of gas flow. 728/730

Pressure Switch

A switch activated by rise or fall in pressure.

A manual reset version requires pushing a

button to transfer the contacts when the

pressure set point is satisfied.

840

Pressure Gauge A device to indicate pressure. 940

Check Valve

A check valve permits flow only in one

direction and is used to prevent back flow of

gas.

780

Strainer A strainer traps sediment to prevent blockage

of sensitive components downstream.

Flexible Connector Flexible connectors isolate components from

vibration, mechanical, and thermal stresses.

Heat Exchanger Heat exchangers transfer heat from one

medium to another. 500

Pressure Taps Pressure taps measure static pressure.

Symbol Appearance Name Remarks Bulletin/

Info Guide

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Eclipse Furnnox Operating instructions

Eclipse Furnnox Operating instructions

Eclipse Furnnox Operating instructions

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